WIKA CPP120-X User manual

Operating instructions
Betriebsanleitung
EN
DE
Pneumatic comparison test pump, model CPP120-X
Pneumatische Vergleichsprüfpumpe, Typ CPP120-X
Preliminary Version
Pneumatic comparison test pump, model CPP120-X

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WIKA operating instructions, model CPP120-X
EN
DE
© 08/2020 WIKA Alexander Wiegand SE & Co. KG
All rights reserved. / Alle Rechte vorbehalten.
WIKA®is a registered trademark in various countries.
WIKA®ist eine geschützte Marke in verschiedenen Ländern.
Prior to starting any work, read the operating instructions!
Keep for later use!
Vor Beginn aller Arbeiten Betriebsanleitung lesen!
Zum späteren Gebrauch aufbewahren!
Operating instructions model CPP120-X Page 3 - 40
Betriebsanleitung Typ CPP120-X Seite 41 - 78
Further languages can be found at www.wika.com.

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Content
Content
1. General information 5
2. Short overview 6
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Description . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . 7
3. Safety 8
3.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . 8
3.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Improper use . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Personnel qualification . . . . . . . . . . . . . . . . . . . 9
3.5 Personal protective equipment . . . . . . . . . . . . . . . . .10
3.6 Labelling, safety marks . . . . . . . . . . . . . . . . . . . 10
4. Design and function 12
4.1 Description . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Instrument base . . . . . . . . . . . . . . . . . . . . . .12
4.3 Pressure supply . . . . . . . . . . . . . . . . . . . . . .15
4.4 Function . . . . . . . . . . . . . . . . . . . . . . . . 15
5. Transport, packaging and storage 17
5.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2 Packaging and storage . . . . . . . . . . . . . . . . . . . 17
6. Commissioning, operation 18
6.1 Unpacking the pneumatic comparison test pump . . . . . . . . . . 18
6.2 Environmental requirement . . . . . . . . . . . . . . . . . . 18
6.3 Assembly of comparison test pump . . . . . . . . . . . . . . . 18
6.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . 19
6.4.1 Connection of the test item and the reference measuring instrument . . .19
6.4.2 Connection of external pressure/vacuum supply . . . . . . . . . . . . . .20
6.4.3 Post-assembly test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.5 Procedure (positive pressure and vacuum operation) . . . . . . . . . 21
6.5.1 Increasing pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.5.2 Decreasing pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6.6 Cleaning gauges . . . . . . . . . . . . . . . . . . . . . 23
7. Faults 24
8. Maintenance, corrective maintenance and cleaning 26
8.1 Periodic maintenance . . . . . . . . . . . . . . . . . . . .26
8.2 Corrective maintenance . . . . . . . . . . . . . . . . . . . 27

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Content
8.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.2.2 Removing the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.2.3 Replacing seals on inlet valve and outlet valve . . . . . . . . . . . . . . .30
8.2.4 Inlet valve and outlet valve testing procedure . . . . . . . . . . . . . . . .30
8.2.5 Volume adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.2.6 Replace sealing of system pressure gauge . . . . . . . . . . . . . . . . .31
8.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 32
9. Dismounting, return and disposal 33
9.1 Dismounting . . . . . . . . . . . . . . . . . . . . . . . 33
9.2 Return . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 34
10. Specifications 35
11. Accessories 39

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1. General information
1. General information
■The model CPP120-X pneumatic comparison test pump described in the operating
instructions has been manufactured using state-of-the-art technology. All components
are subject to stringent quality and environmental criteria during production. Our
management systems are certified to ISO 9001 and ISO 14001.
■These operating instructions contain important information on handling the instrument.
Working safely requires that all safety instructions and work instructions are observed.
■Observe the relevant local accident prevention regulations and general safety
regulations for the instrument's range of use.
■The operating instructions are part of the product and must be kept in the immediate
vicinity of the instrument and readily accessible to skilled personnel at any time. Pass
the operating instructions onto the next operator or owner of the instrument.
■Skilled personnel must have carefully read and understood the operating instructions
prior to beginning any work.
■The general terms and conditions contained in the sales documentation shall apply.
■Subject to technical modifications.
■Further information:
DH-Budenberg
A division of WIKA Instruments Ltd.
- Internet address: www.wika.de / www.wika.com
- Relevant data sheet: CT 91.03
- Application consultant: Tel: [phone]
Fax: [phone]
[email protected].uk
■EU importer
WIKA Alexander Wiegand SE & Co. KG
- Internet address: www.wika.de / www.wika.com
- Relevant data sheet: CT 91.03
- Application consultant: Tel.: [phone]
Fax: [phone]
[email protected]

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2. Short overview
2. Short overview
2.1 Overview
1Test item connection with G ½ female thread, loose union connection
2Connection Block G 1 female thread
3Inlet valve
4Outlet valve
5Volume adjuster
6System pressure gauge
7Rotatable feet
8Inlet manifold (rear side)
2.2 Description
The model CPP120-X comparison test pump is a pneumatic comparison test pump
for the provision of pressure up to 120 bar [1,740 psi]. It is technically identical to the
instrument base of the model CPB3500 dead-weight tester.
The individual test points can be easily controlled with the two integrated fine metering
valves for pressure inlet and pressure outlet.
For the precise setting for accurate comparative testing, the CPP120-X features a
precisely adjustable volume adjuster.
1
2
4
7
1
2
5
6
3
7
8

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2. Short overview
The connection for the necessary external pressure or vacuum supply is located on the
rear side of the instrument.
By connecting the test item and a sufficiently accurate reference pressure measuring
instrument to the test pump, the same pressure will act on both measuring instruments.
By comparison of the two measured values at any given pressure value, a check of the
accuracy and/or adjustment of the pressure measuring instrument under test can be
carried out.
The two test connections are equipped with G ½ female loose union connections.
Corresponding thread adapters are available for the calibration of instruments with
different connection threads.
Any comparison test pump, model CPP120-X can converted to a pneumatic dead-weight
tester by the addition of the appropriate piston cylinder system (CPS3500) and mass set
(CPM3500).
The CPP120-X features optimal characteristics for use in the laboratory, as well as the
ruggedness needed for industrial applications.
The pneumatic comparison test pump requires a regulated supply of clean dry gas to
operate.We recommend using a Nitrogen Cylinder as the gas from this is normally dry
and clean. Alternatively use compressed air, filtered and dried to remove oil and moisture
which could cause that the piston cylinder system or the moveable parts of the base unit
become sticky.
2.3 Scope of delivery
■Instrument base
■Two fine metering valves for pressure inlet and pressure outlet or vacuum
■Volume adjuster for fine pressure adjustment
■Two test item connections with G ½ female thread, loose union connection
■Connection for external pressure or vacuum supply
■Adapter set for test item selectable from 3 different sets:
• Adapter set “BSP” G ½ male on G ⅛, G ¼, G ⅜ and G ½ female
• Adapter set “NPT” G ½ male on ⅛ NPT, ¼ NPT, ⅜ NPT and ½ NPT female
• Adapter set “metric” G ½ male on M12 x 1.5 and M20 x 1.5 female
■Tool and maintenance set
Cross-check scope of delivery with delivery note.

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3. Safety
3. Safety
3.1 Explanation of symbols
WARNING!
... indicates a potentially dangerous situation that can result in serious injury
or death, if not avoided.
CAUTION!
... indicates a potentially dangerous situation that can result in light injuries or
damage to property or the environment, if not avoided.
Information
... points out useful tips, recommendations and information for efficient and
trouble-free operation.
3.2 Intended use
This model CPP120-X pneumatic comparison test pump is used for the testing,
adjustment and calibration of mechanical and electronic pressure measuring instruments
through comparative measurements.
These unit can be used in the laboratory or workshop, or on site at the measuring point.
By connecting the test item and a sufficiently accurate reference pressure measuring
instrument to the test pump, the same pressure will act on both measuring instruments.
By comparison of the two measured values at any given pressure value, a check of the
accuracy and/or adjustment of the pressure measuring instrument under test can be
carried out.
The CPP120-X requires a regulated supply of clean dry gas to operate.We recommend
using a nitrogen cylinder as the gas from this is normally dry and clean.
Alternatively use compressed air, filtered and dried to remove oil and moisture which
could cause that the piston cylinder system or the moveable parts of the base unit
become sticky.
This instrument is not permitted to be used in hazardous areas!
The instrument has been designed and built solely for the intended use described here,
and may only be used accordingly.
The technical specifications contained in these operating instructions must be observed.

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3. Safety
Improper handling or operation of the instrument outside of its technical specifications
requires the instrument to be taken out of service immediately and inspected by an
authorised WIKA service engineer.
The manufacturer shall not be liable for claims of any type based on operation contrary to
the intended use.
3.3 Improper use
WARNING!
Injuries through improper use
Improper use of the instrument can lead to hazardous situations and injuries.
▶Refrain from unauthorised modifications to the instrument.
▶Do not use the instrument within hazardous areas.
▶Do not use the instrument with liquid media.
▶Do not use the instrument to calibrate oxygen gauges.
▶Do not use oxygen as pressure supply.
Any use beyond or different to the intended use is considered as improper use.
3.4 Personnel qualification
WARNING!
Risk of injury should qualification be insufficient
Improper handling can result in considerable injury and damage to property.
▶The activities described in these operating instructions may only be
carried out by skilled personnel who have the qualifications described
below.
Skilled personnel
Skilled personnel, authorised by the operator, are understood to be personnel who,
based on their technical training, knowledge of measurement and control technology and
on their experience and knowledge of country-specific regulations, current standards and
directives, are capable of carrying out the work described and independently recognising
potential hazards.
WIKA can provide dedicated training courses on the correct use of our
products. Please contact your local office for further details.

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3. Safety
3.5 Personal protective equipment
The personal protective equipment is designed to protect the skilled personnel from
hazards that could impair their safety or health during work.When carrying out the various
tasks on and with the instrument, the skilled personnel must wear personal protective
equipment.
Follow the instructions displayed in the work area regarding personal protective
equipment!
The requisite personal protective equipment must be provided by the operating company.
Wear safety goggles!
Protect eyes from flying particles and liquid splashes.
During the operation, cleaning or maintenance at the comparison test pump
it is necessary to wear safety goggles.
Please observe also the additional notes in the individual chapters of this
operating instruction.

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3. Safety
3.6 Labelling, safety marks
Product label
The operator is obliged to maintain the product label in a legible condition.
1Model
2Serial number
3Pressure range
4Date of manufacture)
5Pressure transmission medium
Symbol
Before mounting and commissioning the instrument, ensure you read the
operating instructions!
DH Budenberg
10 Huntsman Drive, Irlam, Manchester, M44 5EG
www.wika.com Made in UK
clean, dry gasesPRESSURE MEDIUM
06/2013MANUFACTURED
120 barMax PRESSURE
CPP120-X/123456SERIAL No
Vergleichsprüfpumpe/Comparison test pump CPP120-X
1
2
3
4
5

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4. Design and function
4. Design and function
4.1 Description
The model CPP120-X pneumatic comparison test pump features optimal characteristics
for use in the laboratory, as well as the ruggedness needed for industrial applications.
The CPP120-X requires a regulated supply of clean dry gas to operate.We recommend
using a Nitrogen cylinder as the gas from this is normally dry and clean. Alternatively use
compressed air, filtered and dried to remove oil and moisture which could cause that the
piston cylinder system or the moveable parts of the base unit become sticky.
4.2 Instrument base
The CPP120-X instrument base consists of a solid aluminium base plate mounted on four
adjustable levelling feet, a volume adjuster, control valves, pipework to two stainless steel
pressure connection blocks.
The pipework and above mentioned assemblies are covered by an easy to clean ABS
cover.
The component identification (number in the circle) in each procedure refer to
the following figure.
1
2
4
7
1
2
5
6
3
7
8

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4. Design and function
1Test item connection with G ½ female thread, loose union connection
As standard, the test item connections 1have a G ½ female thread. For calibrating
instruments with other connection threads, the appropriate thread adapter can be
used see chapter 11 "Accessories").
Instead of a test item connection 1, a model CPS3500 piston cylinder
system can directly mounted at the connection block 2.
This enables to use the CPP120-X in combination with a model
CPM3500 mass set as a pneumatic dead weight tester.
2Connection block G 1 female thread
Pressure supply pipes from the volume adjuster are terminated at two pressure
blocks mounted on the base.
The connection blocks are fitted with an G 1 female thread at the top which will come
through the cover of the base.The connection blocks enable to screw in the test item
connections 1.
3Inlet valve
The inlet valve control the pressure supply into the instrument base.
■By turning the inlet valve anti-clockwise, the pressure is increased.
■By turning the inlet valve clockwise, the pressure increase is stopped.
CAUTION!
Damage of the inlet valve caused by overtightening
Overtightening of the valve will result a shorter working life and thus
involve maintenance.
▶The valve has a ‘soft seat’ design and should only require to be finger-
tight to achieve an effective seal.

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4. Design and function
4Outlet valve
The outlet valve control the pressure release out of the instrument base.
■By turning the outlet valve anti-clockwise, the pressure is reduced.
■By turning the outlet valve clockwise, the pressure reduction is stopped.
CAUTION!
Damage of the outlet valve caused by overtightening
Overtightening of the valve will result a shorter working life and thus
involve maintenance.
▶The valve has a ‘soft seat’ design and should only require to be finger-
tight to achieve an effective seal.
5Volume adjuster
To reach the test pressure very accurate and fast, the instrument base is equipped
with a volume adjuster.These is particularly required when calibrating high accuracy
instruments.
6System pressure gauge
The system pressure gauge gives an indication only of the approximate pressure
which is in the system.
⇒This gauge is not intended for calibrating other instruments.
7Rotatable feet
The instrument base consists of four adjustable levelling feet.
By adjusting the four knurled feet on the rotatable feet, the test pump can be
alignend, by placing the supplied spirit level.
8Inlet manifold
The inlet manifold is bolted to the rear of the aluminium base plate. The external
pressure supply should be connected here.

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4. Design and function
4.3 Pressure supply
The CPP120-X requires a regulated pressure supply of clean dry gas to operate.
Any compressed pressure supply represents a supply of considerable potential energy
and as with electricity precautions must be taken to prevent accidents.
WARNING!
Physical injuries and damage to property and the environment caused
by incorrect pressure supply
Improper handling can result in considerable injury and damage to
equipment.
▶Use only dry, clean and oil-free gases (e.g. Nitrogen cylinder).
▶Use a pressure reducer to reduce the supply pressure.The supply
pressure should be just above the required working pressure max. 120 bar
[1.740 psi].
▶Do not use oxygen in the tester.
▶If no suitable supply is available use a hand pump for pressure or vacuum
supply.
4.4 Function
Operation of the CPP120-X is by controlling the supply/release of a pneumatic
pressure/vacuum supply by the inlet valve 3and the outlet valve 4. With the use of
the two control valves (and if applicable the system pressure gauge) the operator can
approximately reach the required pressure.
To achieve the exact required pressure the volume adjuster 5should be rotated
clockwise or anti-clockwise to increase or decrease pressure.To release the test pressure
the outlet valve 4has to be turned anti-clockwise.
No excessive force is required on the control valves and or volume adjuster to achieve the
desired results.

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4. Design and function
Schematic diagram
1Test item connection
2Connection block
3Inlet valve
4Outlet valve
5Volume adjuster
6System pressure gauge
9Pressure/vacuum supply
8Inlet manifold
354
2
1
9
8
6
1
1

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5. Transport, packaging and storage
5. Transport, packaging and storage
5.1 Transport
Check the model CPP120-X pneumatic comparison test pump for any damage that may
have been caused by transport.
Obvious damage must be reported immediately.
CAUTION!
Damage through improper transport
With improper transport, a high level of damage to property can occur.
▶When unloading packed goods upon delivery as well as during internal
transport, proceed carefully and observe the symbols on the packaging.
▶With internal transport, observe the instructions in chapter 5.2 "Packaging
and storage".
5.2 Packaging and storage
Do not remove packaging until just before mounting.
Keep the packaging as it will provide optimum protection during transport (e.g. change in
installation site, sending for repair).
Permissible conditions at the place of storage:
■Storage temperature: -10 ... +50 °C
■Humidity: 35 ... 85 % relative humidity (no condensation)
Avoid exposure to the following factors:
■Direct sunlight or proximity to hot objects
■Mechanical vibration, mechanical shock (putting it down hard)
■Soot, vapour, dust and corrosive gases
■Hazardous environments, flammable atmospheres
Store the CPP120-X in its original packaging in a location that fulfils the conditions
listed above. If the original packaging is not available, pack and store the instrument as
described below:
1. Place the instrument along with shock-absorbent material in the packaging.
2. If stored for a prolonged period of time (more than 30 days), place a bag containing a
desiccant inside the packaging.

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6. Commissioning, operation
6. Commissioning, operation
Personnel: Skilled personnel
Protective equipment: safety goggles
Tools: open-end wrench
Only use original parts (see chapter 11 "Accessories").
6.1 Unpacking the pneumatic comparison test pump
As soon as possible after delivery open the packaging of the model CPP120-X pneumatic
comparison test pump and check that all the items detailed in the packing list (see
chapter 2.3 "Scope of delivery") are included.
Unpacking the items, check them for any damage that may have been caused by
transport. If any items are missing, please contact DH-Budenberg/WIKA immediately.
6.2 Environmental requirement
When not sitting the CPP120-X in a temperature controlled laboratory look for an area
that satisfies the following criteria as much as possible:
■A constant temperature area free from draughts and supplies of heat or cold
■An area free from noise and vibration, constantly used pathways
■A clean dry area free from corrosive liquids or vapours
A strong, stable, level table or workbench with the capability of supporting the system with
sufficient space to operate is required.
6.3 Assembly of comparison test pump
Fastening the CPP120-X to the bench
The CPP120-X should be mounted on a firm, level table or bench about 0.9 m [35.4 in]
high.The centre line of the front adjustable feet of the CPP120-X should be about 40 mm
from the front edge of the bench to allow adequate clearance for the volume adjuster 5.
1. Fit the pneumatic comparison test pump on the bench with the adjustable feet on the
level plates and the volume adjuster 5projecting over the front of the bench.
2. Using the spirit level provided and level the unit in both the front/rear axis and the side
to side axis by adjusting the four knurled feet.

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6. Commissioning, operation
If the model CPP120-X pneumatic comparison test pump is used as a dead
weight tester in combination with a model CPS3500 piston cylinder system
the levelling procedure should be carried out after the piston system has
been fitted.
The spirit level should be placed on the weight carrier during the levelling
procedure.
6.4 Assembly
6.4.1 Connection of the test item and the reference measuring instrument
▶The instrument to be tested and the reference measuring instrument are inserted into
the two test connections 1and can be oriented.
⇒It doesn’t matter which port is used for which instrument.
⇒No excess force is required!
As standard, the test connections 1are G ½ female.
For calibrating instruments with other connection threads, the appropriate thread adapter
can be used (see chapter 11 "Accessories").
When using thread adapters, the thread adapter has to be connected
pressure tight to the test item first.
After that the test item with mounted adapter can be inserted into the test
connection 1and can be oriented.
▶Before adapting the reference pressure measuring instrument and the test item, check
the sealings in the two connections for correct seating and wear.
⇒Replace the sealings, if necessary.
CAUTION!
Damage to the hand test pump due to contamination
Contaminants of any kind (oil, grease, water ...) that adhere to the test item
will find their way into the pump and damage it.
▶Ensure that the mating faces are absolutely clean.
▶Clean the connections if necessary.
▶Clean the test item and reference instrument before mounting.
▶To mount or dismount a pressure gauge to the test connections 1a suitable spanner
hast to be used.The spanner has to put only to the spanner flats. Otherwise the
pressure gauge or the comparison test pump can be damaged.
⇒Ensure that the lower part of the gauge connection is not rotated as this may
release the gauge stand from the CPP120-X.

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6. Commissioning, operation
6.4.2 Connection of external pressure/vacuum supply
WARNING!
Physical injuries and damage to property and the environment caused
by incorrect air/gas supply
Improper handling can result in considerable injury and damage to
equipment.
▶Use only dry, clean and oil-free gases (e.g. nitrogen cylinder)
▶Use a pressure reducer to reduce the supply pressure.
⇒The supply pressure should be just above the required working
pressure max. 120 bar [1,740 psi].
▶Do not use oxygen in the tester.
▶If no suitable pressure supply is available use a hand test pump for
pressure or vacuum supply.
CAUTION!
Damage of the test item or reference pressure measuring instrument
caused by too high pressure supply
▶Ensure that the inlet valve 3is closed and outlet valve 4is open before
the CPP120 is pressurised with initial pressure.